Integral spine structure for footwear

ABSTRACT

A support structure for footwear includes a longitudinally extending member to which a plurality of laterally extending supports members are secured at spaced apart locations along a length of the longitudinal member. The support structure may extend along the entire length of a footwear or may be specifically designed for the forefoot, midfoot, or hindfoot areas of a footwear. The support structure may be combined with plate-like structures or may include a plurality of longitudinally extending members. The lateral supports may extend in a generally horizontal plane or may extend in an upward or downward direction out of the horizontal plane. Furthermore, the longitudinal and lateral members may be made of different materials, or each may be made of a plurality of different materials to provide the desired characteristics of the support structure at a given location in the footwear. Different portions of the longitudinal member may be more or less flexible than the lateral supports.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser.No. 60/488,476 filed on Jul. 17, 2003, and entitled INTEGRAL SPINESTRUCTURE FOR FOOTWEAR, the disclosure of which is incorporated hereinby reference in its entirety.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention generally relates to footwear, and morespecifically relates to structures for supporting a footwear.

2. Related Art

A common objective for most types of footwear designs is to address atleast one of the following three biomechanical issues: shockattenuation, stability, and support. Shock attenuation involves theabsorption of shock, shock diffusion and pressure distribution. Theability of a footwear to attenuate shock forces can greatly reduce thepain and discomfort to a user of the footwear for any given application.Shock absorption may be addressed by the type of materials that are usedin the footwear. Various types of materials have excellent shockabsorption properties, especially for the thin layers that are typicallyrequired for a footwear. Shock diffusion relates to dampening of shockforces to reduce how much of the shock force is transferred to the user.Again, the type of material as well as the structure of the footwear maysignificantly affect shock diffusion by a footwear. Pressuredistribution relates to the distribution or spreading out of a pointforce or pressure point such as, for example, a heel strike pressurepoint at the heel of a footwear when walking or running. Pressuredistribution is often accomplished using a plate-like structure whereinthe amount of pressure distribution is controlled by the type andthickness of the plate material.

The stability of a footwear is a another important biomechanical issueand may be controlled by the material properties and structure ofvarious features of a footwear. For example, a footwear with a verythick sole that raises an individual's center of gravity beyond anatural position may provide a very unstable scenario. Further, sometypes of materials used in footwear are very flexible and if used alonewithout any other support features may create an unstable footwear. Sometypes of material that do not allow flexibility may effect the naturalmotion of the foot and further create instability.

The support provided by a footwear is also important. A common objectivefor a footwear is to obstruct as little as possible the naturalmovements of the foot while supporting the foot where it is necessaryfor a given footwear application. In some applications such as sportslike soccer and tennis, lateral support is extremely important, whilearch support and support along the longitudinal axis of the footwear maybe a greater consideration for applications such as running and walking.Other applications that require standing for long periods of time mayrequire the type of support which reduces the amount of work the usersfoot muscles must exert in order to maintain proper posture and balancewhile standing.

A further biomechanical consideration for footwear is the flexibility ofthe forefoot, midfoot and hindfoot portions of the footwear. A naturalmotion of the foot requires significant flexing and bending in alongitudinal direction as well as some complex lateral and torsionalmotion. While some types of inflexibility may be important for certainperformance enhancement objectives, most footwear applications require arange of flexibility in each major section of the footwear. For example,undue amounts of torsional flexibility about a transverse axis of thefootwear in the area of the arch of the foot may result in inadequateguiding and holding of the foot if the footwear bottom also provides toomuch longitudinal flexibility in that region of the footwear.

One known attempt at an “all day comfort” footwear that addresses shockattenuation, stability, support and flexibility includes a firm lastinginsole that is layered in the footwear just above the midsole andextends along the hind of the footwear up to the midfoot of thefootwear. This plate-like structure provides support and diffuses forcesin the heel. In an effort to attenuate shock forces, the footwear mayinclude a gel or other type of insert material at the outsole or withinthe midsole of the footwear. Although the plate structure may distributepressure, the heel strike and other significant shock forces are notdissipated very well. Furthermore, because there is no support structurein the forefoot of the footwear, the footwear may be entirely tooflexible for a given application and fails to provide the torsionalrigidity that is necessary for support and stability of the footwear.

Another known footwear design that attempts to address the biomechanicalissues described above includes a sole structure that has multiplehorizontal and/or vertical layers of foam materials that each havedifferent properties. The outsole may also include certain structuresthat provide some lateral support. This type of design is difficult toalter for the support, stability and shock attenuation needs ofdifferent applications while concurrently providing necessaryflexibility along the length of the footwear.

The cost and feasibility of a footwear design is a further considerationwhen designing a footwear that addresses the above-mentionedbiomechanical issues. Some footwear designs may include materials orstructures that are not conducive to cost effective manufacturing andassembly of the footwear.

SUMMARY OF THE INVENTION

The present invention relates to a support structure for use in afootwear that can be altered to meet the shock attenuation, stability,support and flexibility needs for a given footwear application. Oneaspect of the invention relates to a footwear support structure thatincludes an elongate member and a plurality of lateral supports coupledto the elongate member. In some embodiments, the elongate member may bemore flexible than the lateral supports by using, for example, differentmaterials or different cross-sectional shapes for the elongate memberverses the lateral supports. In other embodiments, the support structuremay have different flexibility properties in the forefoot, midfoot andhindfoot sections of the support structure. The support structure may bepositioned at various locations within a footwear sole assembly betweenvarious layers of the sole assembly. The support structure may also becoupled to a carrier or base member and used as an insert piece in thesole assembly.

Another aspect of the invention relates to a footwear sole structurethat includes a sole member having a heel portion defining a void, and aspine structure that includes an elongate spine extending along a firstaxis and a plurality of laterally extending support ribs secured to theelongate spine at spaced apart locations along a length of the spine.The spine structure is at least partially positioned over the void andsupported by the heel portion of the midsole member, and a portion ofthe spine structure is movable into the void. In other embodiments, thevoid is positioned in other portions of the midsole or another solemember of a footwear sole assembly. The void may be filled with amaterial different properties from the material that defines the void.

Another aspect of the invention relates to a footwear construction thatincludes a midsole member having a heel section that includes first andsecond portions having different properties, an upper member coupled tothe midsole, and a spine support structure that includes an elongatespine member and a plurality of laterally extending supports coupled tothe elongate spine member. The first portion of the heel sectionsupports the laterally extending supports and the second portion of theheel section supports the elongate spine member.

A further aspect of the invention relates to a method of manufacturing afootwear that includes an upper, a sole, and a spine support structurethat includes an elongate spine member and a plurality of transversesupports. The method includes positioning the spine support structure ina mold and positioning the upper adjacent to the mold, filling the moldwith a moldable material to form the sole, and curing the moldablematerial to secure the sole and the spine support structure to theupper.

Another aspect of the invention relates to a method of forming afootwear support structure that includes forming an elongate memberalong a first axis, and forming a plurality of support members that aresecured to the elongate member and that extend in a lateral directionrelative to the first axis.

Another aspect of the invention relates to a method of assembling afootwear support structure that includes an elongate member extendingalong a first axis and a support member. The method may include thesteps of securing the support member to the elongate member, andaligning the support members in a substantially lateral directionrelative to the first axis.

A further aspect of the invention relates to a footwear supportstructure that includes a longitudinal spine structure and a pluralityof support members secured to the spine and that extend in a generallylateral direction relative to a direction of extension of the spinestructure. The support structure may include separate segments havingdifferent stiffening properties unique for certain areas of thefootwear.

Another aspect of the invention relates to a footwear that includes amidsole, an outsole, a lasting insole, an upper, and a support structurepositioned between lasting insole and the outsole. The support structuremay include an elongate member and a plurality of spaced apart laterallyextending supports.

A further aspect of the invention relates to a method of supporting afootwear that includes an upper, a midsole, an outsole, and a supportstructure having a longitudinally extending spine and a plurality oflaterally extending supports secured to the spine at spaced apartlocations along a length of the spine. The steps of the method mayinclude positioning the support structure in the midsole and securingthe midsole to the upper and the outsole.

A further aspect of the invention relates to a method of supporting afootwear having a outsole, a midsole, an upper, and a support structurehaving an elongate spine and a plurality of laterally extending supportssecured to the spine at spaced apart locations along a length of thespine. The method may include positioning the support structure withinthe upper and above the outsole, and resisting lateral movement in thefootwear with the support structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side cross-sectional view of a footwear known in the art.

FIG. 2 is a side cross-sectional view of a footwear having an embeddedsupport structure according to principles of the invention.

FIG. 3 is a bottom plan view of the footwear of FIG. 2.

FIG. 4 is a lateral cross-sectional view of the footwear of FIG. 3 takenalong cross-sectional indicators 4-4.

FIG. 5 is a lateral cross-sectional view of the footwear of FIG. 3 takenalong cross-sectional indicators 5-5.

FIG. 6 is a lateral cross-sectional view of the footwear of FIG. 3 takenalong cross-sectional indicators 6-6.

FIG. 7 is a top view illustrating one example longitudinal memberaccording to principles of the invention that follows a centerline afootwear through the toe and heel centerlines.

FIG. 8 is a top view illustrating another example longitudinal memberaccording to principles of the invention that follows a pressure linefor a footwear.

FIG. 9 is a top view illustrating a further example longitudinal memberaccording to principles of the invention that follows a random line in afootwear.

FIG. 10 is a perspective view of a portion of one example supportstructure according to principles of the invention.

FIG. 11 is a lateral cross-sectional view taken along cross-sectionalindicator 11-11 shown in FIG. 10.

FIG. 12 is a top view of one example support structure that includes thelongitudinal member of FIG. 7.

FIG. 13 is a top view of another example support structure that includesthe longitudinal member of FIG. 8.

FIG. 14 is a top view of anther example support structure that includeslateral supports with a single flared end.

FIG. 15 is a top view of anther example support structure that includeslateral supports with two flared ends.

FIG. 16 is a top view of anther example support structure that includesa longitudinal support that is exposed where attached to the lateralsupports.

FIG. 17 is a top view of anther example support structure that includeslateral supports at a mid section that act as shank for a footwear.

FIG. 18 is a top view of anther example support structure that includesmultiple longitudinal supports.

FIG. 19 is a top view of anther example support structure that includeswebbing material that extends between some of the lateral supports.

FIG. 20 is a top view of anther example support structure that includesa heel plate.

FIG. 21 is a top view of anther example support structure that isconfigured as a blocker unit with connecting webbing between lateralsupports of the support structure.

FIG. 21A is a side view of the blocker unit configuration shown in FIG.21.

FIG. 21B is a side view of another example blocker unit configurationthat includes a layer of connecting webbing above and below the supportstructure.

FIG. 22 is a side cross-sectional view of one example support structureaccording to principles of the present invention mounted in a footwearhaving a continuous flat outsole.

FIG. 23 is a side cross-sectional view of one example support structureaccording to principles of the present invention mounted in a footwearhaving a cut out arch section of the footwear.

FIG. 24 is a side cross-sectional view of one example support structureaccording to principles of the present invention mounted in a footwearhaving a partial cut out arch section of the footwear.

FIG. 25 is a side cross-sectional view of one example support structurewherein the mid section of the support structure is a continuous pieceof material and acts as a shank for the footwear.

FIG. 26 is a side cross-sectional view of another example supportstructure wherein the mid section of the support structure is exposed atthe outsole of the footwear.

FIG. 27 is a side cross-sectional view of another example supportstructure wherein the hindfoot section of the support structure extendsthrough a midsection of the midsole.

FIG. 28 is a side cross-sectional view of one example support structurewherein the mid section of the support structure includes a continuouspiece of material having a longitudinal support with an increasedcross-section.

FIG. 28A is a top perspective view of the support structure shown inFIG. 28.

FIG. 28B is a lateral cross-sectional view taken along cross-sectionalindicator 28B-28B shown in FIG. 28A.

FIG. 29 is a side cross-sectional view of one example support structurewherein the support structure extends along the outsole of the footwear.

FIG. 29A is a top perspective view of the support structure shown inFIG. 29.

FIG. 29B is an lateral cross-sectional view of the footwear shown inFIG. 29 taken along cross-sectional indicators 29B-29B.

FIG. 30 a side cross-sectional view of one example support structurewherein the support structure extends in the middle of the midsole ofthe footwear.

FIG. 31 a side cross-sectional view of one example support structurewherein the support structure includes lateral supports in the toesection and a plate support in the mid section and heel section.

FIG. 31A is a top perspective view of the support structure shown inFIG. 31.

FIG. 32 is a lateral cross-sectional view of an example footwear thatincludes a support structure that includes upward and downward extendinglateral supports.

FIG. 32A is a top perspective view of support structure shown in FIG.32.

FIG. 33 is a top perspective view of another example support structurethat includes upward, downward and horizontally extending lateralsupports.

FIG. 33A is an end view of the support structure shown in FIG. 33.

FIG. 34 is a top perspective view of a portion of the support structureshown in FIG. 16.

FIG. 35 is lateral cross-sectional view of another support structure inwhich the longitudinal support and the lateral support have a coplanartop surface and the longitudinal support includes a curvedcross-section.

FIG. 36 is lateral cross-sectional view of another support structure inwhich the longitudinal support and the lateral support have a coplanartop surface and the longitudinal support includes a rectangularcross-section.

FIG. 37 is lateral cross-sectional view of another support structure inwhich the longitudinal support extends above a top surface of thelateral support and the longitudinal support has a circularcross-section.

FIG. 38 is lateral cross-sectional view of another support structure inwhich the longitudinal support extends across atop surface of thelateral support.

FIG. 39 is a side view of a portion of an example support structure inwhich the lateral support extends continuously along the longitudinalaxis and the longitudinal support extends between the lateral supports.

FIG. 39A is a side cross-sectional view of the support structure shownin FIG. 39 taken along cross-sectional indicator 39A-39A.

FIG. 40 is a side view of a portion of another example support structurein which the longitudinal support extends continuously along thelongitudinal axis and the lateral supports are mounted to thelongitudinal support.

FIG. 40A is a cross-sectional view of the support structure shown inFIG. 40 taken along cross-sectional indicator 40A-40A and furthersupported in a mold.

FIG. 41 is a perspective view of one example support structure accordingto principles of the invention integrated into a padded footwear insert.

FIG. 42A is a top view of forefoot or toe portion of a support structureaccording to principles of the invention.

FIG. 42B is a top view of midfoot portion of a support structureaccording to principles of the invention.

FIG. 42C is a top view of hindfoot or heel portion of a supportstructure according to principles of the invention.

FIG. 43 is a top view of another example support structure according toprinciples of the invention that supports midfoot and hindfoot portionsof a footwear.

FIG. 44 is a top view of another example support structure according toprinciples of the invention that supports forefoot and midfoot portionsof a footwear.

FIG. 45 is a top view of a footwear that includes another examplesupport structure according to principles of the invention that extendsthe entire length of the footwear.

FIG. 46 is a side cross-sectional view of the footwear shown in FIG. 45taken along cross-sectional indicators 46-46.

FIG. 47 is a lateral cross-sectional view of the footwear shown in FIG.45 taken along cross-sectional indicators 47-47.

FIG. 48 is a lateral cross-sectional view of the footwear shown in FIG.45 taken along cross-sectional indicators 48-48

FIG. 49 is a top view of a footwear that includes another examplesupport structure according to principles of the invention that extendsalong a partial length of the footwear.

FIG. 50 is a side cross-sectional view of the footwear shown in FIG. 45taken along cross-sectional indicators 50-50.

FIG. 51 is a lateral cross-sectional view of the footwear shown in FIG.45 taken along cross-sectional indicators 51-51.

FIG. 52 is a lateral cross-sectional view of the footwear shown in FIG.45 taken along cross-sectional indicators 52-52.

FIG. 53 a lateral cross-sectional view of the footwear shown in FIG. 45taken along cross-sectional indicators 53-53.

FIG. 54 is a top perspective view of an example footwear sole insertaccording to principles of the present invention.

FIG. 55 is a side cross-sectional view of an example footwear sole thatincludes the insert member shown in FIG. 54.

FIG. 55A is lateral cross-sectional view of the footwear sole shown inFIG. 55.

FIG. 56 is a side cross-sectional view of an example footwear sole thatincludes separate forefoot and heel sections of the insert member shownin FIG. 54 positioned as outsole members.

FIG. 56A is a lateral cross-sectional view of the footwear sole shown inFIG. 56.

FIG. 57 is a side cross-sectional view of an example footwear sole thatincludes separate forefoot and heel sections of the insert member shownin FIG. 54 positioned respectively adjacent to a midsole and as aportion of the outsole.

FIG. 58 is a side cross-sectional view of an example footwear sole thatincludes separate forefoot and heel sections of the insert member shownin FIG. 54 positioned adjacent to a midsole of the footwear sole.

FIG. 59 is a side cross-sectional view of an example footwear sole thatincludes a support structure secured to an underside of a midsole of awelt sole construction.

FIG. 59A is a lateral cross-sectional view of the footwear sole shown inFIG. 59.

FIG. 60 is a side cross-sectional view of an example footwear sole thatincludes a support structure secured to an underside of a lasting insoleof lasting sole construction.

FIG. 61 is a side cross-sectional view of an example footwear sole thatincludes a support structure completely embedded in an sole insertmember that is positioned as a portion of the footwear outsole.

FIG. 61A is a lateral cross-sectional view of the footwear sole shown inFIG. 61.

FIG. 62 is a side cross-sectional view of example footwear sole thatincludes a support structure molded in the footwear sole in a welt soleconstruction.

FIG. 62A is a lateral cross-sectional view of the footwear sole shown inFIG. 62.

FIG. 63 is a lateral cross-sectional view of another example footwearsole that includes a support structure with lateral supports that extendvertically downward.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention generally relates to a support structure forfootwear. The support structure includes a longitudinally extendingmember to which a plurality of laterally extending supports members aresecured at spaced apart locations along a length of the longitudinalmember. The support structure may extend along the entire length of afootwear or may be specifically designed for the forefoot, midfoot, orhindfoot areas of a footwear. The support structure may be combined withplate-like structures or may include a plurality of longitudinallyextending members. The lateral supports may extend in a generallyhorizontal plane or may extend in an upward or downward direction, orcombination of upward, downward, horizontal or generally curved upwardor downward directions. Furthermore, the longitudinal and lateralmembers may be made of different materials, or each may be made of aplurality of different materials to provide the desired characteristicsof the support structure at a given location in the footwear. In someembodiments, the longitudinal member is more flexible than the lateralsupports. The term “flexible” or “flexibility” is defined as the abilityof a member to flex in various direction under different loads, such asflexibility in bending or in torsion, wherein the member at leasttemporarily changes shape or size. The invention may be more completelyunderstood with reference to the above descriptions and the followingexamples. The examples included herein are given for illustrativepurposes only and should not be construed as limiting the scope of theinvention to what is illustrated and described herein.

An example footwear 10 known in the art is shown in FIG. 1. Footwear 10includes a forefoot section 12, a midfoot section 14, and a hindfootsection 16, and further includes an upper 18, a lasting insole 20, amidsole 22, an upper midsole 23, an outsole 24, and a padded insert 26.The outsole 24 may include a variety of different materials, but istypically made from rubber or a rubber composite material compressionmolded into a given shape. The outsole 24 may be cupped upward, as shownin FIG. 1, so as to extend upward at edges of the outsole to cover thoseparts of the footwear that may otherwise contact the ground. Themidsoles 22, 23 are typically the primary cushioning and shockattenuation components of the footwear and may be one of two types ofconstruction. A first type of construction includes a molded EDAmaterial or polyurethane (typically known as foam or a foam product), asshown in FIG. 1. This type of construction is common in athletic andcasual footwear but also has a wide variety of other uses. The secondtype of construction is a masting design in which the midsole is hardand relatively thin. This type of construction is common for dressfootwear and some types of boots and other work footwear. A paddedinsole 26 may be removable from the footwear, or in other instances maybe bonded to the lasting insole 20.

Footwear 10 is generally orientated along an XYZ coordinate systemwherein the direction along a length of the footwear is the Y direction,the direction transverse across a width of the footwear is the Xdirection, and a direction vertical upward relative to the outsole 24 isthe Z direction. The same or similar reference numbers used to describefeatures of footwear 10 will be used for like components in thefollowing examples.

An example footwear 100 having a support structure 30 according toprinciples of the invention is illustrated with reference to FIGS. 2-6.Footwear 100 includes forefoot, midfoot and hindfoot sections 12, 14,16; an upper 118, a lasting insole 120, a midsole 122, an outsole 124and a padded insert 126. The support structure 30 may include alongitudinally extending support 32 (referred to herein as a “spine”,“elongate spine”, “longitudinal spine”, or “longitudinal member”) and aplurality of laterally extending supports 34 (referred to herein as“ribs”, “support ribs”, “rib supports”, “lateral supports”, or “lateralribs”), and may further include a window 38 that provides viewing into avoid 39 in midsole 122 and outsole 124. The window 38 provides viewingof a portion of support structure 30 after footwear 100 is assembled.Spine 32 may extend along an axis 36 that defines a spatial centerlineor a pressure centerline of footwear 100.

Referring to FIGS. 4-6, a cross-section taken in each of sections 12,14, 16 of footwear 100 illustrate example shapes and configurations forthe spine 32 and ribs 34. The section of spine 32 that corresponds tothe forefoot, midfoot and hindfoot sections of footwear 100 are referredto as spine section 32 a, 32 b, 32 c, respectively. Likewise, groups ofribs 34 corresponding with the forefoot, midfoot and hindfoot sectionsof footwear 100 are referred to as ribs 34 a, 34 b, 34 c, respectively.FIGS. 4-6 illustrate that the ribs and spine may have different shapesand sizes at various locations along a length a support structure 30 inorder to provide the needed support, stability and shock attenuation offootwear 100 at each section of the footwear. Some of these variationswill be described in the further example that follows.

Spine 32 may include first and second ends 48, 50 and extend alongdifferent “centerlines” of a footwear. In one example embodiment shownin FIG. 7, first end 48 is aligned with a toe centerline 42 and secondend 50 is aligned with a heel centerline 40. The axis 36 of spine 32 maychange direction in the midfoot section 32 b. Another example embodimentshown in FIG. 8 includes a spine 32 that follows an axis 36 thatcorresponds to a pressure centerline. of a footwear. In thisconfiguration, first end 48 aligns with a centerline 46 of toe push offpressure and second end 50 aligns with a centerline 44 of heel strikepressure. The curvature of axis 36 shown in FIG. 8 may be altered fordifferent footwear designs depending on the footwear structure and theintended use of the footwear.

A further example embodiment shown in FIG. 9 includes a spine 32 thatfollows a complex centerline pattern. First end 48 in this configurationaligns with a centerline 42 of a footwear toe while the second end 50aligns with a centerline 44 of heel strike pressure. In otherembodiments, the first and second ends 48, 50 may be aligned differentlyor in different combinations of pressure centerlines and featurecenterlines of a footwear than shown in FIGS. 7-9. Furthermore, spine 32may extend along an axis that is offset from the axis 36 shown in FIGS.7-9, or there may be two or more spine members that extend alongdifferent portions of a footwear or that extend across only certainsections of the footwear.

FIG. 10 provides an example support structure 30 that illustrates someof the features and benefits of a support structure disclosed herein.Support structure 30 includes spine 32 and a plurality of ribs 34. Eachrib 34 includes first and second sides 52, 54, a mid section 56 and acut-out portion 58 sized to engage spine 32. Rib 34 may also include aturned-up portion 60 or a turned-down portion 61 at ends of the ribs.Spine 32 and ribs 34 may be made of the same or different materialsdepending on the application for the support structure 30. In oneexample embodiment, ribs 34 are made from a material having lessflexibility than the material of spine 32. In other embodiments, thestructure of spine 32 compared to that of the ribs 34 alone may providegreater flexibility in the spine than in the ribs. In some applicationsit is preferred to have greater flexibility in the spine than in theribs so as to allow flexibility along a length of the footwear atcertain areas of the footwear while providing desired amounts of lateralsupport with the ribs. In other embodiments it is desired to have aspine that has the same flexibility characteristics or being lessflexible than ribs 34 if the intended purpose is to reduce longitudinalflexibility at certain sections in the footwear.

The support structure 30 shown in FIG. 10 illustrates direction ofmotion of ribs 34 about the X, Y and Z-axis. Arrow 66 illustratesrotational motion about the Y-axis, which generally corresponds to anaxis of spine 32, arrow 68 illustrates rotational motion of rib 34 aboutthe Z-axis, and arrow 70 illustrates rotational motion about the X-axis,which axis is generally aligned in a lateral direction across a width ofthe footwear. The amount of movement of ribs 34 about the X, Y andZ-axis may be controlled by both the structure and materials used forribs 34 and spine 32. For example, spine 32 may include differentmaterials in different “zones” of support structure 30 to providevarying amounts of movement of ribs 34 in each zone. In otherembodiments, the cross-section of spine 32 may be such that there islittle flexibility for a given material that would otherwise providegreater flexibility if using a smaller cross-section.

FIGS. 10 and 11 further illustrate features related to an optionalmethod of mounting ribs 34 to spine 32. Although support structure 30may be most easily generated using a co-molding process in which thespine and ribs are secured together during the molding process, thespine 32 and ribs 34 may be separately formed and then individuallymounted to each other. One example of such a separate mounting includesthe use of position fins 72, 74 that extend outward from spine 32 andcorresponding locking recesses 76, 78 formed in rib 34. In thisconfiguration, spine 32 may be inserted into opening 58 in the rib untilposition fin 72, 74 engage locking recesses 76, 78 to hold the rib 34 ina fixed position relative to spine 32. In other embodiments (not shown),spine 32 may include at least one recess formed around a circumferenceof the spine and the rib may include positioning fins extending radiallyinward from aperture 58 of the rib so that the positioning fins of therib engage the recesses formed in the spine to lock the rib into apredetermined position.

FIG. 12 illustrates another support structure 130 that includes a spine132 corresponding to the spine arrangement shown in FIG. 7. First andsecond ends 148, 150 of spine 132 are aligned with respective toe andheel centerlines 142, 140. An axis 136 of spine 132 changes direction inan area corresponding to a midfoot of a footwear and includes generallylinear sections between the first and second ends 148, 150 and the pointat which direction changes. Spine 132 includes forefoot, midfoot andhindfoot sections 132 a, 132 b, 132 c that correspond to groups of ribs134 a,134 b, 134 c. Support structure 130 may also include a heel plate162 secured at second end 150.

FIG. 13 illustrates a support structure 230 that includes a spine 232extending along an axis 236 that is similar to the configuration shownin FIG. 8. First and second ends 248, 250 of spine 232 align withrespective centerlines of toe push-off pressure and heel strike pressure246, 244, and axis 236 follows a pressure centerline of a givenfootwear. Ribs 234 are separated into groups 234 a, 234 b, 234 ccorresponding to the forefoot, midfoot and hindfoot sections of afootwear. Spine 232 includes corresponding zones 232 a, 232 b, 232 c.Support structure 230 may also include a heel plate 262 secured at end250 and a toe plate 264 secured at first end 248.

FIG. 14 illustrates another example support structure 330 that is avariation of support structure 230. The first side 352 of some of theribs in zones 334 b, 334 c include a flared, wider top profile than thesecond side 354 of those same ribs. In addition, the second side 354 ofsome of the ribs 334 a, 334 b are flared so as to have a wider topprofile than the first side 352 of those same ribs. In otherembodiments, different combinations of ribs in various sections of thesupport structure may include flared ends at the first or second sides,or both the first and second sides may include flared ends as shown bysupport structure 430 in FIG. 15. The first and second sides 452, 454 ofsupport structure 430 are flared in a generally oval shape, but may, inother embodiments, have other shapes and different sizes from thoseflares shown in FIGS. 14 and 15.

FIGS. 14 and 15 illustrate support structures 330, 430 in which thespine 332, 432 extends through an internal cavity of each of the ribs334, 434. Support structure 530 shown in FIG. 16 includes a connectionbetween spine 532 and ribs 534 in which the spine 532 is exposed as itpasses through and connects to each of ribs 534. Spine 532 includes apair of position fins 572, 574 at the location where each rib 534 is tobe secured to spine 532, and a corresponding recess 558 is formed inmidsection 556 of each rib. In one embodiment shown in FIG. 34, a topsurface of spine 532 is coplanar with a top primary surface of rib 534.This type of flush mounting of the top surfaces of the spine and ribsmay be advantageous for supporting the lasting insole directly or fordirectly engaging an outsole of a footwear (if the support structure 530is turned upside down). A similar configuration may be useful forsecuring the toe plate 564 and heel plate 562 to the spine 532 atrespective first and second ends 548, 550. Further exampleconfigurations for securing the spine and ribs are shown and describedwith reference to FIGS. 34-38.

FIG. 17 illustrates a variation of support structure 530 in which thespine 532 b associated with ribs 534 b is formed of the same material asthe ribs of that section. Thus, if ribs 534 c include a material thathas little flexibility and spine 532 b includes the same low flexibilitymaterial, the section of support structure 530 associated with themidfoot of a footwear would have less flexibility than those sections ofsupport structure 530 at the forefoot and the hindfoot areas of thefootwear. As a result, the midfoot “zone” of the support structure 530has a low flexibility, which may be useful for replacing a shank elementthat would otherwise be required in the footwear.

FIG. 18 illustrates a yet further variation of support structure 530that includes multiple longitudinally extending spine members 532 a, 532b, 532 c in addition to spine 532. Each of the additional spine members532 a, 532 b, 532 c may have a different curvature and may extend alongdifferent sections of support structure 530. For example, spine member532 c is secured at a first side 552 of ribs 534 between the ribs 534 a,while spine member 532 a is secured at second side 554 and connects ribsalong all sections 532 a, 532 b, 532 c. The additional spine members 532a, 532 b, 532 c may be made of the same material as spine 532, or may bemade of different materials having different properties from spine 532,and may in some instances completely eliminate the need for spine 532.

A yet further variation of support structure 530 is shown in FIG. 19 andincludes a webbing material 580 interposed between and connectingvarious ribs 534 in sections 532 a, 532 b, 532 c. Such a webbing membermay limit movement of the ribs 534 about the Z-axis while stillpermitting movement of the ribs about the X and Y-axis. In someembodiments, webbing 580 may extend between only the second sides ofribs 534, while in other embodiments webbing 580 may extend between onlythe first sides of the ribs 534. A yet further embodiment may includethe configuration shown in FIG. 38 in which webbing 580 further extendsacross a top or a bottom, or both a top and a bottom surface of each ofthe ribs 534.

FIG. 20 illustrates another support structure 630 that includes agreater number of ribs in zones 634 a, 634 b than in those embodimentsshown previously. Support structure 630 includes a heel plate 662 thattakes the place of ribs 634 c. Heel plate 662 includes recesses 682 a-dto increase the flexibility in the heel plate 662. Support structure 630also includes a toe plate 664. In yet further embodiments, rib 634 a and634 b may be even narrower and closely spaced apart than theconfiguration shown in FIG. 20, or such ribs may replace the heel plate662 within zone 634 c and plate 662 may replace ribs 634 a or ribs 634b.

Another example support structure 730 shown in FIG. 21 may be used as ablocker unit that can be cut or otherwise formed for use in multiplefootwear sizes. For example, an outer periphery 784 of support structure730 may be used for one footwear size, or the support structure 730 maybe cut or otherwise formed to have the smaller outer periphery 786 suchthat support structure 730 may fit in a smaller footwear size. Therelatively simple design of spine 732 and ribs 734 may be advantageousfor providing consistent performance of support structure 730 in any ofseveral sizes.

FIGS. 21A and 21B illustrate side views of possible configurations forsupport structure 730 when using a webbing 780 between and/or aroundribs 734. FIG. 21A illustrates rib 734 encapsulated between layers ofwebbing 780 and connected together with spine 32. As discussed above,webbing 780 may be made of the same or different materials from spine732. FIG. 21 b shows webbing 780 between ribs 734. In some embodiments,the webbing and spine may be colored differently than each other anddifferent from ribs 734 so that a side view of the footwear provides avisual indicator of certain features of support structure 730.

FIGS. 22-31 are cross-sectional views taken along a length of an examplefootwear and illustrate various example footwear and support structureembodiments. In any of these examples or other embodiments using theprinciples disclosed herein, the support structure may be secured to afootwear in a number of ways. One example securing method includesmolding a portion of the footwear around the support structure and thensecuring that portion of the footwear to the remaining portions of thefootwear. Another method may include forming a portion of the footwearwith recessed areas sized to receive the support structure such that thesupport structure may be “dropped in” to the recess. In a yet furthermethod, the support structure may be configured as a complete layer thatcan be added as a separate layer during construction of a footwear.

Each of the examples shown in FIGS. 22-31 include forefoot, midfoot andhindfoot sections 12, 14, 16, an upper 18, a lasting insole 20, amidsole 22, an outsole 24, and a support structure 30 having a spine 32and ribs 34. Some of the examples further include an upper midsole 23.These features have been referenced in each figure. Of further note,many of the layers and features shown in FIGS. 22-31 are not shown withcomplete cross-section hatching so as to more clearly illustrate thevarious features shown in those figures.

An example footwear 200 having a generally flat outsole 24 is shown inFIG. 22. Outsole 24 is generally flat and extends along forefoot,midfoot and hindfoot sections 12, 14, 16. Support structure 30 ismounted in midsole 22 along an upper portion of the midsole 22 adjacentthe lasting upper 20 and further includes toe and heel plates 64, 62 atopposing first and second ends 48, 50 of spine 32.

Another example footwear 300 having a heel breast 108 shown in FIG. 23.Footwear 300 includes a support structure 30 that has a longitudinallyextending spine 32, lateral support structures or ribs 34, at a heelplate 62. The outsole 24 and midsole 22 are recessed in the area ofmidsole 14 so as to create a heel portion of the footwear defined byheel breast 108. The upper midsole 23 may be co-molded with midsole 22or may be a separate midsole member made of a different material havingdifferent properties than midsole 22. For example, upper midsole 23 maybe a firm, plate-like layer or a foam having little flexibility whilemidsole 22 includes a foam having greater flexibility. Support structure30 is positioned along an upper part of midsole 22 adjacent to uppermidsole 23, but may in other embodiments be positioned above the uppermidsole 23 or within other areas of midsole 22.

Example footwear 400 shown in FIG. 24 includes a “fiddle” shank 88. Afiddle shank is constructed such that the midfoot region 14 includesrecesses in the midsole and outsole portions, but includes a shank-likefeature made from the midsole and outsole that extends downward to besupported by the ground in the area of midfoot 14. In some embodiments,the recessed portion of the fiddle shank area may be recessed completelyin a vertical direction so as to expose a portion of support structure30, or may include a window feature so as to view a portion of thesupport structure either from a side or a bottom view of footwear 400.

A yet further example footwear 500 shown in FIG. 25 includes a supportstructure 30 having a section of the support structure acting as ashank. Support structure 30 includes a plurality of ribs 34 a and aspine 32 a in the region of forefoot 12, ribs 34 b and spine 32 b in thearea of midfoot 14, and ribs 34 c and spine 32 c in the area of hindfootsection 16. Another example support structure having similar features isshown as support structure 530 in FIG. 17. Spine 32 b and ribs 34 b maybe made of the same or similar materials so as to have a reducedflexibility in the midfoot section 14 where additional support istypically desired because of the recesses in midsole 22 and outsole 24that define the heel breast 108. Footwear 500 may also include a window38 through outsole 24 for viewing a portion of support structure 30 froma bottom side of the footwear.

A further example of footwear 600 having a portion of a supportstructure 30 exposed at a bottom side of the footwear is shown in FIG.26. Support structure 30 includes separate zones or sections along alength of the footwear, which include a spine 32 a and ribs 34 a at theforefoot 12, spine 32 b and ribs 34 b at midfoot 14 and spine 32 c andribs 34 c at hindfoot section 16. The spine 32 b and ribs 34 b may havesignificantly larger cross-sectional sizes as compared to the spine andribs in other sections of the footwear, and may be made of material thathas a greater resistance to wear and increased resistance to deformationbecause of its exposure outside of the footwear. The material in thissection of support structure 32 may also have less flexibility, or maybe the same material as the other sections of the support structure, buthave less flexibility as a whole because of the larger cross-section ofthat section. In other embodiments, there may be additional or fewerlayers that midsole 22 and upper midsole 23, or there may be layers ofmidsole between the lasting insole 20 and the support structure features34 b, 34 b. The ribs 34 b may be covered by a protective coating such asa clear polyurethane material to protect the ribs 34 b from damage.

An example footwear 700 having a portion of the support structure 30that extends into a midsection of the midsole 22 is shown in FIG. 27.Support structure 30 has at least three sections or zones that alignwith the forefoot, midfoot or hindfoot sections 12, 14, 16. A forefootsection of support 30 includes spine 32 a and a plurality of ribs in 34a that extend along an upper portion of midsole 22 adjacent the lastinginsole. A second section or zone includes a spine 32 b and a pluralityof ribs 34 b that are enlarged in comparison to features of the othersupport structure sections, and extend along an upper area of midsole 22adjacent the lasting insole 20. A third section includes a spine 32 cand a plurality of ribs 34 c at the hindfoot section of the footwearthat extend into a midsection of midsole 22 between the lasting insole20 and outsole 24. Support structure 30 may also include a heel plate 62and a toe plate 64. Further, footwear 700 may include a window 38 in themidfoot section 14 of the footwear for viewing the support structurefrom a bottom side of the footwear.

An example footwear 800 that includes an alternative shank-like featurein the support structure 30 is shown in FIGS. 28, 28 a and 28B. Supportstructure 30 may include at least three separate zones or sections thatare align with the forefoot, midfoot and hindfoot sections of thefootwear. A forefoot section of the support structure includes a spine32 a and a plurality of ribs 34 b along with a toe plate 64. A midfootsection of the support structure may include a spine 32 b with asubstantial height and width along with a plurality of ribs 34 b. Thesize and materials of spine 32 b and ribs 34 b they provide a shank-likefeature for footwear 800. A hindfoot section of the support structuremay include spine 32 c and a plurality of ribs 34 c have a differentcross-section and shape than the other sections of the supportstructure. As with many of the other examples described herein, thefeatures of support structure 30 may be turned upside down and mountedat a bottom side of midsole 22 so as to extend the long outsole 24rather than extending along lasting insole 20.

An example footwear 900 that includes a support structure 30 withfeatures facing upward such that the support structure extends along anoutsole of footwear (as mentioned above) is shown in FIGS. 29, 29A and29B. The support structure 30 extends along midsole 22 adjacent tooutsole 24 and further includes upward extending support structures 60at opposing ends of the ribs 34 a and 34 c. The spine 32 b extendsthrough midfoot section 14 and may be configured to extend along thelasting insole 20 as well as the outsole 24. The ribs 34 b in midfootsection 14 may be a single plate as shown in FIG. 29A or maybe aplurality of ribs similar to ribs 34 a and 34 c. Support structure 30may also include a heel plate 62 and a toe plate 64.

A further example of footwear 1000 that includes a support structureextending through a midportion of midsole 22 is shown in FIG. 30. Thesupport structure 30 includes a spine 32 and a plurality of ribs 34, andmay further include a heel plate 62 and a toe plate 64. A supportstructure 30 may extend through a mid portion of midsole 22 so as to bespaced between the lasting insole 20 and the outsole 24 along the entirelength of support structure 30 from a first end 48 to a second end 50,or may in other embodiments extend along the outsole and the lastinginsole, or both the lasting insole and the outsole at various locationsalong a length of the support structure.

An example footwear 1100 that includes a support structure 30 having anextended plate feature in combination with a spine and plurality of ribsis shown in FIG. 31. The support structure 30 includes a plate-likestructure similar to heel plate 62 that extends along the hindfoot andmidfoot sections 16, 14, and further includes a forefoot section havinga spine 32 a and a plurality of ribs 34 a, including a toe plate 64.This particular embodiment may be useful for providing lateral supportand additional pressure dissipation in high impact areas in the hindfootand midfoot sections of the footwear while providing necessaryflexibility with limited lateral support through the forefoot section ofthe footwear. FIG. 31A illustrates one example support structure 30 thatincludes features illustrated in FIG. 31. The heel plate 62 may includea cupping fin or wall 63 that extend upward or downward (not shown) thatcan be used to engage portions of the midsole 22, outsole 24, upper 18,or other portions of the footwear 1100.

FIGS. 32-38 illustrate several further example support structureembodiments, any of which may be included in the above listed examples.One example support structure 830 that includes upward and downwardextending ribs 90, 92 is shown in FIGS. 32, 32A. Support structure 830includes a longitudinally extending spine member 32 and a plurality ofupward extending lateral supports or ribs 92 as well as a plurality ofdownward extending lateral supports or ribs 90. Each of the ribs 90, 92may further include generally vertically extending tabs or supports 60at ends of the ribs. As shown in FIG. 32A, the vertical support 60 mayextend along an exterior side wall of the midsole or extend upward tosupport a vertically extending portion of an upper 18 of a footwear1200. A footwear 1200 may include a window 38 that is viewable througheither lasting insole 20 and midsole 22 from a top of the footwear, orfrom a bottom of the footwear through outsole 24 and midsole 22. Infurther embodiments, a window may be positioned along a sidewall of themidsole so as to view the support structure 30 from a side or back ofthe footwear.

The upward extending tabs 60 may be configured to extend outside of thesole structure of footwear 1200 and around the upper 18 as a strapfeature 65 in FIG. 32. The strap 65 may be integrally coupled to one ofthe ribs 90, 92, or any other portion of the support structure 830. Thestrap 65 may be detachable for optional use, or may extend onlypartially around the upper 18 such that strap 65 includes multiplepieces that are separately coupled to portions of the upper 18.

Another support structure example embodiment 930 is shown in FIGS. 33and 33 a. Support structure 930 includes a longitudinally extendingspine 32, at least one horizontally extending lateral support or rib 34,at least one downward supporting lateral support or rib 34, at least onedownward extending lateral support or rib 90, and at least one upwardextending lateral support or rib 92. Each of ribs 34, 90, 92 may includea vertical tab or extension 60, or a vertically downward extending tab,such as tab 61 shown in the following FIG. 36.

FIG. 34 illustrates a close-up perspective view of a portion of thesupport structure 530 shown in FIG. 16. As discussed above related toFIG. 16, spine 32 includes a top surface that is generally coplanar witha top surface of rib 34, and includes position fins 72, 74 that engagerib 34 to hold rib 34 in position relative to the spine 32. This type ofconfiguration could be either upward (as shown) or downward facingdepending on whether the support structure 530 is aligned adjacent alasting insole of the footwear or against the outsole of the footwear.

The spine 32 shown in FIG. 34 has a partial cylindrical cross-sectionand rib 34 is generally flat between first and second sides 52, 54. Inother embodiments shown in FIGS. 35-38, spine 32 may have a parabolic,cylindrical, rectangular, or combination of cylindrical and rectangularcross-sections. Furthermore, a top surface of the rib 34 may have agenerally upwardly sloping curvature (to mirror the curvature of thelasting insole) that may further include vertically upward or verticallydownward extending tabs 60, 61.

Support structure 1030 shown in FIG. 35 includes one example spine 32with a parabolic cross-section and a top surface that is flush with atop surface of rib 34. A midsection 56 of rib 34 in support structure1030 generally outlines the parabolic shape of the spine 32. Supportstructure 1130 shown in FIG. 36 includes a spine with a rectangularcross-section and the midsection 56 has a shape that is unrelated to theshape of the spine. The top surface of spine 32 is coplanar with the topsurface of the rib 34. Support structure 1230 shown in FIG. 37 includesa spine with a cylindrical cross-section that extends above an uppersurface of rib 34. This configuration may be useful when the supportstructure 1230 is embedded in a midsole rather than being flush againstan outsole or a lasting insole of a footwear. Support structure 1330shown in FIG. 38 includes a spine 32 with a partial cylindricalcross-section and further includes an extension 32 d that extends acrossat least a portion of rib 34 beyond midsection 56. In some embodiments,the spine material 32 d may extend across the entire upper surface ofrib 34 and may further extend in between a plurality of ribs positionedalong a length of the spine to act as a webbing between the ribs.

The support structure shown in FIGS. 34-38 may be especially useful forco-molding the support structure or for creating a configuration inwhich the ribs 34 can be snap fit or otherwise separately secured tospine 32 using methods other than co-molding.

FIGS. 39-40 illustrate two examples of co-molding arrangements. Supportstructure 1430 shown in FIGS. 39 and 39A include a spine 32, ribs 34,and right and left flex sections 94, 96 of rib 34. Each rib 34 isconnected via a longitudinal connector 98 such that the ribs 34 areconnected together in a continuous string. Once the string of ribs 34 ismolded, the spine 32 may be co-molded using around longitudinalconnector 98 and to flex sections 94, 96 using mold 100. This type ofmolding may provide advantages of strength and performance when usingthe support structure 1430, as well making it easier to handle the ribsduring manufacture of the support structure.

A support 1530 is shown in FIGS. 40 and 40A having a continuallongitudinal extending spine 32 that is held in a mold 101 and co-moldedwith ribs 34 having flex sections 94, 96 around the spine 32. This typeof construction may also provide certain performance and manufacturingadvantages over other support structure designs. A molded structuremanufactured using the examples shown in FIGS. 39 and 40 may be verycost effective for both initial tool and die preparation and ongoingproduction of parts over time.

A support structure as disclosed herein may be integrated into variousportions of the sole of a footwear (described above), or may beintegrated into a padded insert 126 for a footwear, as shown in FIG. 41.Insert 126 includes a support structure 30 that includes alongitudinally extending spine 32 and a plurality of laterally extendingsupports or ribs 34 that are secured to the spine 32. Support structure30 may also include a heel plate 62 and a toe plate 64 and may alsoinclude vertically extending tabs 60 formed at ends of the ribs 34.Support structure 30 is encapsulated within a padding 27 that provides acomfortable interface between support structure 30 and a user foot, andfurther provide an proper interface between the support structure 30 anda lasting insole or other feature of the footwear.

Any of the above examples, including the padded insert 126 show in FIG.1 may include one or multiple sections of a support structure at variouslocation along a length of a footwear. For example, FIGS. 42A, 42B, 42Cillustrate separate support structure sections that may be used forcertain forefoot, midfoot or hindfoot sections of a footwear. Forefootinsert 102 shown in FIG. 42A includes a spine 32 a that extends along apressure centerline and further includes a plurality of laterallyextending supports or ribs 34 a and a toe plate 64. Midfoot insert 103includes a longitudinally extending spine 32 b and a plurality oflaterally extending supports or ribs 34 b. Hindfoot insert 104 shown inFIG. 42C includes a longitudinally extending spine 32 c and a pluralityof laterally extending support or ribs 34 c as well as a heel plate 62.Spine sections 32 a, 32 b, 32 c shown in FIGS. 42A-C may extend along apressure centerline of a footwear or may be aligned with an actualcenterline of the footwear. Furthermore, the ribs 34 a, 34 b, 34 c mayhave a variety of different shapes and sizes and be aligned relative tothe respective spine member at a variety of different angles.

A yet further example embodiment may include a combined hindfoot andmidfoot insert 105 shown in FIG. 43, or a combined forefoot and midfootinsert 106 shown in FIG. 44. Insert 105 includes spine sections 32 b and32 c as well as groups of ribs 34 b and 34 c. Likewise, insert 106includes spine sections 32 a, 32 b as well as ribs 34 a, 34 b.

In addition to the separate “zones” or sections of the spine or groupsof ribs discussed above, the spine material between each individual ribmay also vary along the length of the support structure. In oneembodiment, the spine material between every rib member may have adifferent composition or set of physical characteristics. In anotherexample, the spine material beginning at the toe and heel areas is veryflexible and the spine material becomes less flexible between every ribor between every few ribs leading toward the midfoot region of thesupport structure.

In a yet further embodiment, the support structure may include aplurality of wire or hair-like laterally or vertically extending supportstructures that extend from either the ribs or the spine for specializedsupport in certain areas of a footwear.

Referring now to FIGS. 45-48, an example footwear sole assembly 1601that includes a support structure 1630 is shown and described. Thesupport structure 1630 is shown extending along substantially the entirelength of the footwear sole assembly 1601. The support structureincludes a longitudinal spine 1632 and lateral support 1634 that extendin only the midfoot section 1603 and hind foot section 1604. Theforefoot section 1602 includes a plate-like structure 1662 that mayinclude a plurality of recesses 1635 to increase flexibility of theplate structure. Various features of the support structure 1630cooperate with features of the midsole 1622 and outsole 1624 of thefootwear sole assembly 1601, as described below.

The longitudinal spine 1632 and lateral supports 1634 may have differentconfigurations along the length of the footwear to provide desiredresults in the footwear sole assembly 1601. In many cases, it ispreferable to provide high shock absorption and shock attenuation in thehindfoot portion of a footwear. To address these criteria, the hindfootportion 1632 c of the longitudinal spine is relatively small in crosssection and may include a recessed portion to increase flexibility ofthe spine where the spine attaches to the lateral supports 1634 c in thehindfoot portion 1604. A spine insert piece 1633 may be inserted in therecessed portion (see FIGS. 46 and 47), wherein the insert piece 1633may include different flexibility properties or other characteristics tohelp “fine tune” the support structure characteristics for a givenfootwear. The longitudinal spine 1632 c may also include differentmaterials from the lateral supports 1634 c that also promotes increasedflexibility spine and movement of the lateral supports relative to thespine.

The lateral support 1634 c may be relatively long and narrow as shown inFIG. 45 or may be relatively short and wide depending on the desiredresult. Ends of the lateral supports 1634 c opposite the longitudinalspine 1632 c may be supported on a support shelf 1683 defined by arecess 1681 in the midsole 1622. A separate void 1685 formed in themidsole 1622 beneath the remaining portions of the lateral support 1634c and the longitudinal spine portion 1632 c establish a trampoline-likedesign that provides the desired shock attenuation and shock absorptionbenefits while still providing sufficient support due to the remainingrelatively firm midsole material around a periphery of the hindfootsection of the footwear sole assembly 1601.

A separate spine support member 1687 may be positioned within the void1685 in a further effort to “fine tune” overall performance of thesupport structure 1630. This member 1687 may either partially orcompletely fill the void 1685, and preferably is position in alignmentthe longitudinal spine section 1632 c (see FIG. 47) to provideengagement of the spine when a load is applied to the spine structure1630.

The midfoot section of a footwear typically requires greater stiffnessto support the arch of a users foot. In many footwear constructions, ashank member is required to bridge between the forefoot of the footwearand the heel portion of the footwear defined by a heel breast. Thesupport structure 1630 may be modified to include different materials ora different structure to provide the desired support and stiffness. Thelongitudinal spine portion 1632 b includes a greater cross sectionalarea, which in combination with the shorter length of lateral support1632 b and the absence of a recess or void beneath the support structurein the midfoot portion of the footwear, results in a shank-likestructure or effect. An alternative embodiment of a support structurethat includes a shank-like structure is shown with reference to FIGS.49-53.

In many types of footwear, the forefoot area is relatively thin forpurposes of aesthetics and styling. The preferred reduced thickness inthe forefoot is in conflict with another objective to provide additionalsupport, shock absorption, and shock attenuation in the forefoot tobalance toe off forces and the like when the footwear is used forwalking, which objective typically requires additional thickness in theforefoot area. The support structure 1630 is modified in the forefootarea 1602 to eliminate the lateral supports 1634 and a definedlongitudinal spine 1632 and to include a plate-like structure 1662 thatis surrounded by first and second forefoot padding layer 1689, 1691. Theforefoot section 1602 may be configured such that the first paddinglayer 1689 may be flush with a top surface of the midfoot and hindfootsections 1603, 1604 as shown in FIG. 46. Other embodiments may use asingle padding layer in the forefoot or may replace the plate-likestructure with a material or member that includes more flexibilityand/or padding.

The footwear sole assembly 1601 may also include a viewing window 1638that is positioned vertically below the hindfoot section 1604 to provideviewing of some of the support structure features. The window 1638 maybe embedded in the outsole 1634 and may include a clear polymer materialor other material that provides the desired viewing. Multiple viewingwindows may be provided at different locations along a length of thesupport structure 1630 (e.g., see viewing window 38 in FIGS. 27 and 28).Preferably, the window 1638 is aligned with an open portion of the void1685, the materials of the midsole 1322 and support member 1687 betweenthe window 1638 and the support structure 1630 must be clear as well inorder for viewing to occur. In other embodiments in which the supportstructure is positioned at a bottom side of the midsole rather than at atop side of the midsole, a window through the outsole alone may provideviewing of the support structure. Other embodiments may include aviewing window from a top side of the support structure, such as througha lasting insole or mast layer of the footwear sole assembly.

Referring now to FIGS. 49-53, another footwear sole assembly 1701 isshown and described. Assembly 1701 includes a support structure 1730having midfoot and hindfoot longitudinal spine portions 1732 b, 1732 cand a plurality of lateral supports 1734, and a midsole 1722. Themidsole 1722 includes a void 1785, a recess 1781 that defines a shelf1783, and a spine support member 1787 positioned in the void 1785. Amidfoot section 1703 of the support structure 1730 includes alongitudinal spine section 1732 b having a greater cross-sectional areathan spine portion 1732 c in the heel section 1704 thereby providing ashank-like function. Because of the relatively narrow width of themidsole 1722 as compared to midsole 1622 shown in FIG. 45, the additionof lateral supports small enough to fit with the relatively wide spineportion 1732 c within that width may not be as useful in providingadditional support, shock absorption, and shock attenuation.

The spine support member 1787 completely fills the void 1785 andmaintains contact with the spine portion 1732 c. Other embodiments mayinclude a reduced size spine support member or no spine support memberat all, wherein the void 1785 is left completely open for free movementof the spine structure within the void 1785 (movement of the spinestructure in void 1785 being restricted by at least the support oflateral supports 1743 c on shelf 1783).

In the embodiments shown and described with reference to FIGS. 45-53,the hindfoot portion of the support structures may be generallydescribed as being able to move within a void portion in the midsolewhen a load is applied to the support structure. More specifically, thelongitudinal spine portion in the hindfoot section of the footwear soleassembly may be capable of moving within the voided portion or against acompression or shock absorbing member positioned within the void. Thesame or similar structure may be added in other portions of a footwearsole assembly such as in the forefoot of the assembly if sufficientthickness is provided in the midsole to establish such a void andmovement of the support structure within the void or against a materialpositioned in the void. Using a first material to support ends of thelateral support members and a second material to support at least aportion of the longitudinal spine or the remaining portions of thelateral supports may be particularly useful to meet the demands of shockabsorption and shock attenuation while providing desired support in afootwear assembly.

FIG. 54 illustrates a footwear sole insert 1807 that includes a supportstructure 1830 coupled to a base portion 1809. The insert includesforefoot, midfoot and hindfoot sections 1802, 1803, 1804. The supportstructure 1830 includes a portion of the longitudinal member 1832 andmultiple lateral supports 1834 in each of the forefoot, midfoot andhindfoot portions of the insert 1807. The insert 1807 may beparticularly useful when assembling a footwear sole assembly such as thesole assembly shown in FIGS. 55 and 55A. When the base portion 1809 isconfigured as an outsole member, the insert 1807 may be secured to anunder side of an outsole portion 1824, which is in turn coupled to amidsole 1822 and further coupled to an upper of a footwear (not shown).The base portion 1809 may include any desired material with any desiredshape, such as, for example, a material having slip resistant propertiesthat is formed in shapes that enhance resistance to the footwearslipping.

When using molding processes to generate a footwear assembly such asassembly 1801, the insert 1807 may first be separately formed bycoupling the base member 1809 to the support structure 1830 using suchmethods as, for example, molding, heat or sound welding, or adhesives toprovide a single insert member. The insert may be placed within a moldcavity and the outsole 1824 and midsole 1822 are molded around theinsert 1807 in separate steps. The outsole and insole members 1824, 1822may be separately molded or formed and later coupled to other componentsof the footwear sole assembly 1801 rather than using direct molding ontop of the insert 1807.

The insert 1807 may have a width that is narrower than a total width ofthe outsole 1824 as shown in FIG. 55A, or may extend across an entirewidth of the footwear sole assembly as shown in the embodimentillustrated in FIG. 56A. The insert 1807 may also have a length thatextends along an entire length of the footwear sole assembly and mayfurther extend upward to engage an upper of the footwear if desired(see, for example, the dotted line numbered 99 in FIG. 55). Referring toFIGS. 59 and 59A, the footwear 2300 includes an outsole 2324 and asupport structure 2330 that could be formed as an insert member, aportion of which extends an entire length of the footwear 2300 andengages the upper 2318.

The insert sections 1802, 1803, 1804 may be divided into separate piecesthat are individually insertable into different portions of a footwearsole assembly. For example, FIG. 56 illustrates a footwear sole assembly1901 that include forefoot and hindfoot insert sections 1902, 1904 thatare positioned in an outsole 1924 at respective forefoot and hindfootsections of the assembly. The base member 1909 may be configured as anoutsole member wherein base member 1909 couples the support structure1930 against the outsole 1924. A midsole 1922 may be molded or otherwisecoupled to the outsole 1924 to complete the footwear sole assembly.

FIGS. 57 and 58 illustrate footwear sole assemblies 2001, 2101 that eachinclude insert sections positioned at alternative positions with respectto the outsole. Assembly 2001 includes a forefoot section 2002positioned between the outsole 2024 and the midsole 2022, and a hindfootsection 2004 positioned at a bottom side of the outsole 2024. Assembly2101 includes forefoot and hindfoot sections 2102, 2104 that arepositioned at a top side of the outsole 2124 along an underside of themidsole 2122. Other embodiments may include insert segments at otherlocations within a footwear sole assembly such as on a top side of amidsole or completely embedded within an outsole or insole member.

Referring again to FIGS. 59 and 59A, the footwear 2300 may be wellsuited for a welt type molding or forming process in one method, thesupport structure 2330 is positioned in a mold cavity with stand-offmembers (not shown) that hold the support structure vertically above afloor of the mold cavity. The mold cavity is then filled underneath andaround the support structure using injection molding, casting, or othermethods in which a material such as, for example, a polyurethane foam ora TPU elastomer, fills a portion of the mold cavity to form the outsole2324. The midsole 2322 is either directly molded on top of the supportstructure 2330 and outsole 2324, or is formed separately and thencoupled to the support structure 2330 and outsole 2324. In anothermethod, the outsole 2324 is formed in a mold cavity with a dummy supportstructure in place to create a recess shaped like the actual support,wherein the dummy support structure is later replaced with the actualsupport structure 2330 before adding the midsole or other layers of thefootwear 2300. In a still further embodiment, the support structure iscombined with three or more sole layers as shown in the footwear soleassembly 2601 shown in FIGS. 62 and 62A. Assembly 2601 includes asupport structure 2630 positioned between an outsole 2624, a firstmidsole 2622, and a second midsole 2633. The midsole layers 2622, 2633(and any other midsole or outsole described herein) may include gels,air pockets, or specialized shock absorbing and shock attenuatingmaterials that are sealed within the assembly 2601 to enhanceperformance of the footwear sole assembly.

These types of processes may be useful for interchanging supportstructures with a variety of different designs. For example, the midfootportion 2303 of the support structure may include a longitudinal memberand lateral supports configured to provide a shank-like function. Sizeand shape modifications to the support structure can be accounted foreasily when using molding and related methods to form portions of afootwear sole as described above.

Referring now to FIG. 60, another example footwear 2400 is shownincluding an outsole 2424, a lasting insole 2422, and a supportstructure 2430. The lasting insole 2422 may be separately coupled to anupper 2418 before being secured to the outsole 2424 using any desiredmethods such as the molding methods described above. In one examplemethod, the combined lasting insole 2422 and upper 2418 may be directlymolded or otherwise coupled to the outsole 2424 using, for example,adhesives, cements, or other bonding materials.

Referring now to FIG. 61, another example footwear sole assembly 2501 isshown in which the support structure 2530 is completely embedded withinthe base member 2509 so as to provide an insert 2507 in which none ofthe support structure is exposed. Other embodiments may include exposedportions of the support structure along sides of the insert 2507, butnot at top and bottom surfaces of the insert 2507. The insert 2507 maybe combined within an outsole 2524 and midsole 2522 using any of themethods described above.

Any of the example inserts described above may be configured as ablocker unit that can be trimmed to fit any size footwear desired. Whenthe insert is used as a blocker, end portions of the lateral supportsmay be removed as part of the trimming process.

In an additional embodiment illustrated in FIG. 63, a footwear soleassembly 2701 includes a support structure 2730 having lateral supports2734 that extend in a vertically downward direction from thelongitudinal member 2732. The support structure 2730 is positionedbetween an outsole 2724 and a midsole 2722. The downward sloping lateralsupports 2734 provide a configuration in which the support structure2730 acts as a spring-like member, wherein ends of the lateral members2734 at an outside edge of the assembly 2701 maintain a relatively fixedposition due to the reduced amount of outsole material between theground and the lateral support, and the longitudinal member 2732 isvertically movable due to compressibility of the larger amount ofoutsole material between longitudinal member 2732 and the ground beneaththe outsole 2724. This type of configuration could also be modified intoa blocker style unit in which the lateral members extend out to afurther width as shown by the dash lines in FIG. 63, wherein the lateralmembers are preferably always covered by material of the outsole orinsole 2722, 2724. With the lateral members at their maximum width, itmay be possible to obtain a maximum “spring” effect, although a narrowerconfiguration as shown by the solid lines in FIG. 63 may still provide adesired amount of shock absorption and shock attenuation while providingadditional lateral support that may not otherwise be present if thesupport structure 2730 were removed from the assembly 2701.

Materials for the spine and ribs of the support structure may include,for example, metals and metal alloys, nylon, polyurethane,polypropylene, or any of a variety of other polymer and syntheticmaterials. The materials may include fillers such as glass that increasethe hardness and reduce flexibility of the structures. In one example,the spine support structure material includes at least about 10% glass,and preferably includes about 30% or more glass.

The above specification, examples and data provide a completedescription of the manufacture and use of the composition of theinvention. Since many embodiments of the invention can be made withoutdeparting from the spirit and scope of the invention, the inventionresides in the claims hereinafter appended.

1. A footwear sole structure, comprising: a sole member having a heelportion, the heel portion including an upper surface, a lower surfaceand opposing side surfaces, the heel portion having a width dimensionmeasured between the opposing side surface, the heel portion defining acavity that extends from the upper surface towards the lower surface andat least a portion of the cavity has a width dimension that is less thanthe width dimension of the heel portion; and a spine structure includingan elongate spine extending along a first axis and a plurality oflaterally extending support ribs secured to the elongate spine at spacedapart locations along a length of the spine, a portion of the spinestructure being positioned over the cavity; wherein the spine structureis movable into the cavity relative to the sole portion.
 2. The footwearsole structure of claim 1, further comprising a compressible materialpositioned in the cavity and configured to engage the spine structure.3. The footwear sole structure of claim 1, wherein the sole member is amidsole of a footwear.
 4. The footwear sole structure of claim 1,wherein the sole member includes a viewing window through which at leasta portion of the spine structure is viewable from outside the footwearsole structure.
 5. The footwear sole structure of claim 1, wherein theviewing window is positioned vertically above the spine structure. 6.The footwear sole structure of claim 1, wherein the viewing window ispositioned vertically below the spine structure.
 7. The footwear solestructure of claim 1, wherein the spine structure includes at least twodifferent materials.
 8. The footwear sole structure of claim 7, whereinthe spine structure includes a first elongate portion that includes afirst material, and a second elongate portion that includes a secondmaterial, the second elongate portion at least partially engaged withina recess defined in the first elongate portion.
 9. The footwear solestructure of claim 8, wherein the second elongate portion is positionedin at least a heel portion of the spine structure.
 10. The footwear solestructure of claim 1, wherein the cavity of the heel portion is definedby at least two parallel side walls of the heel portion.
 11. Thefootwear sole structure of claim 10, wherein the sole member furtherincludes a midfoot portion, and a portion of the spine structure isconfigured to include a shank member that extends into the midfootportion of the sole member, the shank member being defined by a portionof the elongate spine having a greater width than the portion of theelongate spine positioned at the heel portion of the sole.
 12. Thefootwear sole structure of claim 11, wherein the portion of the spinestructure that extends into the midfoot portion includes a portion ofthe elongate spine member and at least one support rib.
 13. The footwearsole structure of claim 11, wherein the portion of the spine structurethat extends into the midfoot portion of the sole member has differentflexibility properties than that portion of the spine structurepositioned at the heel portion of the sole member.
 14. The footwear solestructure of claim 11, further comprising a compressible materialpositioned in the cavity and configured to engage the spine structure.15. The footwear sole structure of claim 1, wherein the sole memberincludes a forefoot section, and at least a portion of the spinestructure extends into the forefoot section.
 16. The footwear solestructure of claim 15, wherein that portion of the spine structure thatextends into the forefoot section includes a plate-shaped member. 17.The footwear sole structure of claim 16, wherein the plate-shaped memberincludes a plurality of recessed portions.
 18. The footwear solestructure of claim 16, wherein the plate-shaped member includes aportion of the elongate spine member and at least one support rib. 19.The footwear sole structure of claim 17, wherein at least some of theplurality of recessed portions define through holes.
 20. The footwearsole structure of claim 15, further comprising a first forefoot paddinglayer arranged in engagement with an upper surface of the spinestructure that extends into the forefoot section of the sole member. 21.The footwear sole structure of claim 20, further comprising a secondforefoot padding layer arranged in engagement with a lower surface ofthe spine structure that extends into the forefoot section of the solemember.
 22. The footwear sole structure of claim 20, wherein the firstforefoot padding layer includes a plurality of recessed portions. 23.The footwear sole structure of claim 22, wherein at least some of theplurality of recessed portions in the first forefoot padding layerdefine through holes.
 24. A footwear, comprising: a midsole memberextending in a generally horizontal plane, the midsole member having aheel section that includes first and second portions having differentcushioning properties, the first portion defining a cavity that extendsfrom an upper surface towards a bottom surface of the midsole, thesecond portion positioned within the cavity; an outsole member coupledto a bottom surface of the midsole member and defining an outer surfaceof the footwear configured to engage a ground surface; a upper membercoupled to the midsole; and a spine support structure that includes anelongate spine member and a plurality of laterally extending supportscoupled to the spine portion; wherein the first portion of the heelsection supports the laterally extending supports and the second portionof the heel section supports the elongate spine member, and the spinesupport structure is movable within the cavity relative to the firstportion of the heel section and the outsole member.
 25. The footwear ofclaim 24, wherein the second portion of the heel section includes arecessed portion along the upper surface adjacent a periphery of thecavity that defines a support surface, and end portions of the laterallyextending support are supported on the support surface.
 26. The footwearof claim 24, wherein the first and second portions of the heel sectionhave different compression properties.
 27. The footwear of claim 24,wherein the elongate spine member and the laterally extending supportshaving different flexibility properties.
 28. The footwear of claim 24,wherein the spine support structure includes different flexibilityproperties along a length of the spine support structure.
 29. Thefootwear of claim 24, wherein at least a portion of the spine supportstructure is positioned between the midsole member and the upper member.30. The footwear of claim 24, wherein at least a portion of the spinesupport structure is positioned below a bottom surface of the midsolemember.
 31. The footwear of claim 24, wherein a portion of the spinesupport structure is positioned above a top surface of the midsolemember, and another portion of the spine support structure is positionedwithin the midsole member.
 32. The footwear of claim 24, furthercomprising an outsole member coupled to a bottom side of the midsolemember, and at least a portion of the spine support structure ispositioned between a top surface of the midsole member and a bottomsurface of the outsole member.
 33. The footwear of claim 24, furthercomprising a viewing window through which at least a portion of thespine structure is viewable from outside of the footwear.
 34. Thefootwear of claim 24, wherein at least one of the laterally extendingsupport ribs includes a first portion extending in a generallyhorizontal plane and a second portion extending out of the horizontalplane.